Download Roberts Gorden VANTAGE NP CTHN-200 Service manual

FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Leave the building.
6. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.
7. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
Vantage NP
®
Negative Pressure
Unitary or Multiburner
Infrared Heater
Installation,
Operation &
Service Manual
Fire Hazard
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
CTHN-40
CTHN-60
CTHN-80
CTHN-100
CTHN-125
CTHN-150
CTHN-175
CTHN-200
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or property
damage. Read the Installation, Operation and Service
Manual thoroughly before installing or servicing
this equipment.
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Roberts-Gordon, LLC
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: 716.852.4400
Fax: 716.852.0854
Toll Free: 800.828.7450
Quality in Any Language™
© Copyright 2006 Roberts-Gordon, LLC
www.rg-inc.com
P/N 152101NA Orig 06/06
TABLE OF CONTENTS
SECTION 1: Heater Safety...................................................... 1
1.1 Manpower Requirements ............................................. 1
SECTION 2: Installer Responsibility ..................................... 2
2.1 Wall Tag ....................................................................... 2
2.2 Corrosive Chemicals.................................................... 2
2.3 National Standards and Applicable Codes .................. 2
SECTION 3: Critical Considerations ..................................... 3
3.1 Required Clearances to Combustibles......................... 3
SECTION 4: National Standards and Applicable Codes ..... 7
4.1 Gas Codes................................................................... 7
4.2 Aircraft Hangars ........................................................... 7
4.3 Public Garages ............................................................ 7
4.4 Electrical ...................................................................... 7
4.5 Venting......................................................................... 7
4.6 High Altitude ................................................................ 7
SECTION 5: Heater Descriptions........................................... 8
5.1 Unitary vs. Multiburner................................................. 8
SECTION 6: Major Components ............................................ 9
SECTION 7: General Suspension Details ........................... 10
SECTION 8: Unitary Linear & U-Tube Heater Installation.. 11
8.1 Standard Parts........................................................... 11
8.2 Unitary Heater Requirements .................................... 13
8.3 Unitary Linear Heater Layouts ................................... 14
8.4 Unitary U-tube Heater Layouts .................................. 17
8.5 Burner Tube Installation ............................................ 19
8.6 Tube Clamp Package Installation .............................. 19
8.7 Coupling and Tube Assembly.................................... 20
8.8 Turbulator Installation ................................................ 21
8.9 Reflector Installation .................................................. 22
8.10 Burner Installation.................................................... 24
8.11 Fan Inlet Plate and Warning Tag ............................. 24
8.12 Restrictor Plate Installation ..................................... 25
8.13 Fan Installation ........................................................ 25
SECTION 9: Multiburner Heater Installation ....................... 26
9.1 Standard Parts........................................................... 26
9.2 Multiburner System Design Requirements ................ 29
9.3 Burners Per Pump ..................................................... 30
9.4 Radiant Tube Length.................................................. 31
9.5 Manifold Tube ............................................................ 31
9.6 Multiburner System Layouts and Manifold Tube
Length Rules .............................................................. 31
9.7 Burner Tube Installation ............................................ 36
9.8 Tube Clamp Package Installation .............................. 36
9.9 Coupling and Tube Assembly.................................... 37
9.10 Turbulator Installation .............................................. 38
9.11 Reflector Installation ................................................ 39
9.12 Burner Installation.................................................... 41
SECTION 10: Optional Heater Accessories ........................ 42
10.1 Elbow Package Configuration .................................. 42
10.2 Reflector Side Extension.......................................... 44
10.3 Lower Clearance Shield Installation......................... 45
10.4 Two-Foot Decorative Grille Installation..................... 45
10.5 One-Foot Decorative Grille Installation .................... 47
10.6 Protective Grille Installation...................................... 49
SECTION 11: Venting - General............................................ 50
11.1 General Venting Requirements................................. 50
SECTION 12: Venting - Unitary Heater ................................ 51
12.1 Unvented Operation ................................................. 51
12.2 Unvented Operation Termination ............................. 51
12.3 Horizontal Venting ................................................... 51
12.4 Vertical Venting........................................................ 51
12.5 Length Requirements .............................................. 51
12.6 Flue Connection Detail ............................................ 52
12.7 Horizontal Ventilation 4" (10 cm) Pipe ..................... 52
12.8 Vertical Ventilation 4" (10 cm) Pipe.......................... 53
12.9 Common Sidewall Venting....................................... 53
12.10 Common Vertical Venting ..................................... 54
SECTION 13: Venting - Multiburner Systems ..................... 55
13.1 General Requirements............................................. 55
13.2 Manifold Tube Requirements ................................... 55
13.3 Venting the Pump .................................................... 55
13.4 EP-100 Pump Models .............................................. 56
13.5 EP-200 Pump Series ............................................... 56
13.6 EP-300 Pump Series ............................................... 56
13.7 Installation Precautions............................................ 56
SECTION 14: Outside Combustion Air Supply .................. 58
14.1 Length Requirements .............................................. 58
14.2 Vertical Non-Pressurized Outside Air Supply for
Single Heater Installation ......................................... 58
14.3 Horizontal Non-Pressurized Outside Air Supply for
Single Heater Installation ......................................... 58
14.4 Vertical Non-Pressurized Outside Air Supply for
Double Heater Installation........................................ 59
14.5 Horizontal Non-Pressurized Outside Air Supply for
Double Heater Installation........................................ 59
14.6 Pressurized Outside Air Supply ............................... 60
SECTION 15: Wiring.............................................................. 61
15.1 Internal Wiring ......................................................... 61
15.2 Internal Wiring ......................................................... 61
15.3 Ladder Diagram ....................................................... 62
15.4 External Wiring (Unitary Heaters Only) ................... 62
15.5 Line Voltage Thermostat Wiring
(Unitary Heaters Only) ............................................. 63
15.6 Low Voltage Thermostat Wiring
(Unitary Heaters Only) ............................................. 63
15.7 System Control Methods and External Multiburner
Wiring....................................................................... 64
SECTION 16: Gas Piping...................................................... 69
SECTION 17: Operation and Maintenance.......................... 70
17.1 Checking the Gas Line ............................................. 70
17.2 Unitary Heater Sequence of Operation ................... 70
17.3 Multiburner System Operation.................................. 70
17.4 Maintenance............................................................. 73
17.5 Maintenance Checklist ..............................................74
SECTION 18: Troubleshooting............................................. 76
18.1 Troubleshooting Flow Chart - Unitary ...................... 76
18.2 Troubleshooting Flow Chart - Multiburner................ 78
18.3 Manifold Gas Pressure Setting ................................ 80
SECTION 19: Replacement Parts List ................................. 81
SECTION 20: General Specifications.................................. 83
20.1 Material Specification .............................................. 83
20.2 Heater Specifications............................................... 83
20.3 Suspension Specifications ...................................... 83
20.4 Controls Specifications ............................................ 83
SECTION 21: The ROBERTS GORDON® Vantage® NP Limited
Warranty.......................................................... 85
© 2006
All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon, LLC.
Printed in U.S.A.
TABLE OF FIGURES
Figure 1: Standard Reflector ..................................................... 3
Figure 2: One Side Reflector..................................................... 4
Figure 3: Two Side Reflectors ................................................... 4
Figure 4: 45° Tilt Reflector ........................................................ 4
Figure 5: U-Tube, Standard Reflector........................................ 5
Figure 6: U-Tube, 45° ................................................................ 5
Figure 7: U-Tube, Opposite 45° Reflector ................................. 5
Figure 8: 2-Foot Deco Grille, 1-Foot Deco Grille and
Protective Grille .......................................................... 6
Figure 9: Lower Clearance Shield............................................. 6
Figure 10: Venting ..................................................................... 6
Figure 11: Major Component Descriptions ................................ 9
Figure 12: Critical Hanger Placement ..................................... 10
Figure 13: Linear Heater Assembly Overview......................... 14
Figure 14: Unitary Linear Layout Overviews ........................... 15
Figure 15: Unitary Linear Layout Overviews (Continued) ....... 16
Figure 16: U-tube Assembly Overview.................................... 17
Figure 17: Unitary U-Tube Layout Overviews.......................... 18
Figure 18: Typical CTHN Multiburner System Installation ....... 29
Figure 19: Flag Layout ............................................................ 32
Figure 20: Modified In-Series Layout ...................................... 32
Figure 21: T Layout ................................................................. 33
Figure 22: Fork Layout ............................................................ 34
Figure 23: Herringbone Layout ............................................... 35
Figure 24: Reflector Joint Detail .............................................. 43
Figure 25: Fan Termination ..................................................... 51
Figure 26: Tailpipe Connection Points..................................... 55
Figure 27: Roof Venting of Pump ............................................ 56
Figure 28: Side Wall Venting Configurations........................... 57
Figure 29: General System Control Wiring (Multiburner) ........ 64
Figure 30: External Wiring Diagram EP-100 and
EP-201 120 V 1 Ø Pump (Multiburner) .................. 65
Figure 31: External Wiring Diagram EP-301 230 V 1 Ø Pump
(Multiburner) .......................................................... 65
Figure 32: External Wiring Diagram EP-203 or
EP-303 3 Ø Pump (Multiburner) ............................ 66
Figure 33: One Zone Operation without Control Panel
(Multiburner) .......................................................... 67
Figure 34: Two Zone Operation without Control Panel
(Multiburner) .......................................................... 68
Figure 35: Gas Connection with Flexible Gas Hose ............... 69
Figure 36: Vacuum Differential Reading.................................. 72
SECTION 1: HEATER SAFETY
SECTION 1: HEATER SAFETY
Your Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and
following the warnings in these
sections.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas-fired heating
equipment.
Read this manual carefully before installation,
operation or service of this equipment.
This heater is designed for heating nonresidential
indoor spaces. Do not install in residential spaces.
These instructions, the layout drawing, local codes
and ordinances, and applicable standards that apply
to gas piping, electrical wiring, venting, etc. must be
thoroughly understood before proceeding with the
installation.
Thin sheet metal parts, including the aluminum
reflector and the various venting components, have
sharp edges. To prevent injury, the use of work
gloves is recommended. The use of gloves will also
prevent the transfer of body oils from the hands to the
surface of the reflector.
Before installation, check that the local distribution
conditions, nature of gas and pressure, and
adjustment of the appliance are compatible.
1.1 Manpower Requirements
To prevent personal injury and damage to the heater,
two persons will be required for installation.
1
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 2: INSTALLER RESPONSIBILITY
The installer is responsible for the following:
• To install the heater, as well as the gas and
electrical supplies, in accordance with applicable
specifications and codes. Roberts-Gordon
recommends the installer contact a local Building
Inspector or Fire Marshal for guidance.
• To use the information given in a layout drawing
and in the manual together with the cited codes
and regulations to perform the installation.
• To install the heater in accordance with the
clearances to combustibles requirements.
• To furnish all needed materials not furnished as
standard equipment.
• To plan location of supports.
• To provide access to burners on all sides for
burner servicing and removal.
• To provide the owner with a copy of this
Installation, Operation and Service Manual.
• To never use heater as a support for a ladder or
other access equipment and never hang or
suspend anything from heater.
• To ensure there is adequate air circulation around
the heater and to supply air for combustion,
ventilation and distribution in accordance with
local codes.
• To safely and adequately install heater using
materials with a minimal working load of 75 lbs
(33 kg).
2.1 Wall Tag
A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Please contact Roberts-Gordon or
your ROBERTS GORDON® independent distributor
to obtain the wall tag. Affix the tag by peeling off the
backing of the adhesive strips on the rear surface
and position the tag on a wall near the heater (e.g.
thermostat or ROBERTS GORDON® Controller).
A copy of the wall tag (P/N 91037912) is illustrated on
the back cover. For an immediate solution, you may
affix this copy on the wall near the heater.
Know your model number and installed configuration.
Model number and installed configuration are found
on the burner and in the Installation, Operation and
Service Manual. See Page 3, Figure 1 through Page
6, Figure 10. Write the proper clearance dimensions
in permanent ink according to your model number
2
and configuration in the open spaces on the tag.
2.2 Corrosive Chemicals
CAUTION
Do not use heater in an area containing corrosive
chemicals.
Avoid the use of corrosive chemicals to ensure a
longer life of the burner, tubing and other parts.
Failure to follow these instructions can result in
property damage.
Roberts-Gordon cannot be responsible for ensuring
that all appropriate safety measures are undertaken
prior to installation; this is entirely the responsibility of
the installer. It is essential that the contractor, the
sub-contractor, or the owner identifies the presence
of combustible materials, corrosive chemicals or
halogenated hydrocarbons* anywhere in the
premises.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen elements
(fluorine, chlorine, bromine, etc.). These compounds are
frequently used in refrigerants, cleaning agents, solvents, etc. If
these compounds enter the air supply of the burner, the life span
of the heater components will be greatly reduced. An outside air
supply must be provided to the burners whenever the presence
of these compounds is suspected. Warranty will be invalid if the
heater is exposed to halogenated hydrocarbons.
2.3 National Standards and Applicable Codes
All appliances must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installations in public garages, aircraft hangars,
etc. may be applicable.
SECTION 3: CRITICAL CONSIDERATIONS
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Required Clearances to Combustibles
WARNING
Clearances are the required distances that
combustible objects must be away from the heater to
prevent fire hazards. Combustible materials that may
catch fire include common items such as wood,
paper, rubber, fabric, etc. Maintain clearances to
combustibles at all times for safety.
Clearances for all heater models are located on the
burner of the heater and on Page 3, Figure 1 through
Page 6, Figure 10 in this manual. Check the
clearances on each burner for the model heater
being installed to make sure the product is suitable
for your application and the clearances are
maintained. Read and follow the safety guidelines
below:
• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this heater or any other
appliance.
• Maintain clearances from heat sensitive material,
equipment and workstations.
• Maintain clearances from vehicles parked below
the heater.
• Maintain clearances from swinging and overhead
doors, overhead cranes, vehicle lifts, partitions,
storage racks, hoists, building construction, etc.
• In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to maintain
Fire Hazard
Some objects will catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapors the
required clearances to combustibles away from heater.
Failure to follow these instructions can result in death,
injury or property damage.
required clearances from the heater to the
combustibles. Signs must be posted adjacent to
the heater thermostat. In the absence of a
thermostat, signs must be posted in a
conspicuous location.
• Consult local Fire Marshal, Fire Insurance Carrier
or other authorities for approval of proposed
installation when there is a possibility of exposure
to combustible airborne materials or vapors.
• Hang heater in accordance to the minimum
suspension requirements on Page 10, Figure 12.
• If the radiant tubes must pass through the building
structure, be sure that adequate sleeving and fire
stop is installed to prevent scorching and/or fire
hazard.
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.
FIGURE 1: STANDARD REFLECTOR
Model
A
(inches)
B
C
CTHN-40
5
20
41
20
13
51
104
51
CTHN-60
5
27
51
27
13
69
130
69
CTHN-80
5
30
58
30
13
76
147
76
CTHN-100
5
32
60
32
13
81
152
81
CTHN-125
5
35
65
35
13
89
165
89
CTHN-150
5
39
71
39
13
99
180
99
CTHN-175
8
44
74
44
20
112
188
112
CTHN-200
8
47
76
47
20
119
193
119
D
A
(centimeters)
B
C
D
3
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.
.
FIGURE 2: ONE SIDE REFLECTOR
A
C
B
D
Model
A
(inches)
B
C
CTHN-40
5
6
46
20
13
15
117
51
CTHN-60
5
6
55
27
13
15
140
69
CTHN-80
5
6
64
30
13
15
163
76
CTHN-100
5
6
66
32
13
15
168
81
CTHN-125
5
6
69
35
13
15
175
89
CTHN-150
5
6
75
39
13
15
191
99
CTHN-175
8
6
77
44
20
15
196
112
CTHN-200
8
6
79
47
20
15
201
119
Model
A
(inches)
B
C
D
A
CTHN-40
5
16
47
16
13
41
119
41
CTHN-60
5
18
56
18
13
46
142
46
CTHN-80
5
21
65
21
13
53
165
53
CTHN-100
5
23
68
23
13
58
173
58
CTHN-125
5
26
73
26
13
66
185
66
CTHN-150
5
30
76
30
13
76
193
76
CTHN-175
8
32
88
32
20
81
224
81
CTHN-200
8
33
90
33
20
84
229
84
Model
A
(inches)
B
C
D
A
CTHN-40
8
4
35
43
20
10
89
109
CTHN-60
8
4
45
45
20
10
114
114
CTHN-80
9
4
54
55
23
10
137
140
CTHN-100
10
4
57
56
25
10
145
142
CTHN-125
10
4
63
58
25
10
160
147
CTHN-150
10
4
66
61
25
10
168
155
CTHN-175
10
4
69
68
25
10
175
173
CTHN-200
10
4
73
71
25
10
185
180
D
A
(centimeters)
B
C
D
FIGURE 3: TWO SIDE REFLECTORS
A
C
B
D
(centimeters)
B
C
D
FIGURE 4: 45° TILT REFLECTOR
4
(centimeters)
B
C
D
SECTION 3: CRITICAL CONSIDERATIONS
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.
FIGURE 5: U-TUBE, STANDARD REFLECTOR
CTHN-40
(inches)
A
B
C
D
- UNAPPROVED -
(centimeters)
A
B
C
D
- UNAPPROVED -
CTHN-60
5
27
56
19
13
69
142
48
CTHN-80
5
30
61
20
13
76
155
51
CTHN-100
5
32
63
20
13
81
160
51
CTHN-125
5
35
66
20
13
89
168
51
CTHN-150
5
39
73
21
13
99
185
53
CTHN-175
8
44
75
26
20
112
191
66
CTHN-200
8
47
76
30
20
119
193
76
Model
FIGURE 6: U-TUBE, 45°
CTHN-40
(inches)
A
B
C
D
- UNAPPROVED -
(centimeters)
A
B
C
D
- UNAPPROVED -
CTHN-60
8
4
47
40
20
10
119
102
CTHN-80
8
4
54
46
20
10
137
117
CTHN-100
8
4
57
48
20
10
145
122
CTHN-125
8
4
63
53
20
10
160
135
CTHN-150
8
4
66
56
20
10
168
142
CTHN-175
8
4
69
59
20
10
175
150
CTHN-200
8
4
73
63
20
10
185
160
Model
A
B
D
C
FIGURE 7: U-TUBE, OPPOSITE 45° REFLECTOR
CTHN-40
(inches)
A
B
C
D
- UNAPPROVED -
(centimeters)
A
B
C
D
- UNAPPROVED -
CTHN-60
8
45
45
10
20
114
114
25
CTHN-80
9
55
54
10
23
140
137
25
CTHN-100
10
56
57
10
25
142
145
25
CTHN-125
10
58
63
10
25
147
160
25
CTHN-150
10
61
66
20
25
155
168
51
CTHN-175
10
68
69
20
25
173
175
51
CTHN-200
10
71
73
20
25
180
185
51
Model
A
B
C
D
5
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.
FIGURE 8: 2-FOOT DECO GRILLE, 1-FOOT DECO GRILLE AND PROTECTIVE GRILLE
(inches)
(centimeters)
Model
A
B
C
D
A
B
C
A
C
B
D
D
CTHN-40
5
20
41
20
13
51
104
51
CTHN-60
5
27
51
27
13
69
130
69
CTHN-80
5
30
58
30
13
76
147
76
CTHN-100
5
32
60
32
13
81
152
81
CTHN-125
5
35
65
35
13
89
165
89
CTHN-150
5
39
71
39
13
99
180
99
CTHN-175
8
44
74
44
20
112
188
112
CTHN-200
8
47
76
47
20
119
193
119
Model
A
(inches)
B
C
D
A
CTHN-40
5
25
22
25
13
64
56
64
CTHN-60
5
30
27
30
13
76
69
76
CTHN-80
5
37
37
37
13
94
94
94
CTHN-100
5
39
39
39
13
99
99
99
CTHN-125
5
41
41
41
13
104
104
104
CTHN-150
5
43
50
43
13
109
127
109
FIGURE 9: LOWER CLEARANCE SHIELD*
A
C
B
D
(centimeters)
B
C
D
CTHN-175
- UNAPPROVED -
- UNAPPROVED -
CTHN-200
- UNAPPROVED -
- UNAPPROVED -
F
A
(centimeters)
E
F
*When installed in the first 10' (3 m).
FIGURE 10: VENTING
A
Unvented
Radiant Tubes
Vented
6
E
Vent
Pipes
F
Model
A
(inches)
E
CTHN-40
14
18
18
36
46
46
CTHN-60
14
18
18
36
46
46
CTHN-80
20
24
18
51
61
46
CTHN-100
20
24
18
51
61
46
CTHN-125
20
24
18
51
61
46
CTHN-150
20
30
18
51
76
46
CTHN-175
20
30
18
51
76
46
CTHN-200
20
30
18
51
76
46
SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES
SECTION 4: NATIONAL STANDARDS AND
APPLICABLE CODES
4.1 Gas Codes
The type of gas appearing on the nameplate
must be the type of gas used. Installation must
comply with national and local codes and
requirements of the local gas company.
United States: Refer to National Fuel Gas Code,
ANSI Z223.1 - latest revision (same as NFPA
54).
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.
4.2 Aircraft Hangars
Installation in aircraft hangars must be in
accordance with the following codes:
United States: Refer to Standard for Aircraft
Hangars, ANSI/NFPA-409 - latest revision.
Canada: Refer to Standard CAN/CGA B149.1
and B149.2: Installation Codes for Gas Burning
Appliances.
• In aircraft storage and servicing areas, heaters
shall be installed at least 10' (3 m) above the
upper surface of wings or of engine enclosures
of the highest aircraft which may be housed in
the hangar. The measurement shall be made
from the wing or engine enclosure (whichever is
higher from the floor) to the bottom of the heater.
• In shops, offices and other sections of aircraft
hangars communicating with aircraft storage or
servicing areas, heaters shall be installed not
less than 8' (2.4 m) above the floor.
• Suspended or elevated heaters shall be so
located in all spaces of aircraft hangars that they
shall not be subject to injury by aircraft, cranes,
movable scaffolding or other objects. Provisions
shall be made to assure accessibility to
suspended heaters for recurrent maintenance
purposes.
4.3 Public Garages
Installation in garages must be in accordance
with the following codes:
United States: Standard for Parking Structures
NFPA-88A - latest revision or the Code for Motor
Fuel Dispensing Facilities and Repair Garages,
NFPA-30A - latest revision. Canada: Refer to
CAN/CGA B149.1 and B149.2: Installation
Codes for Gas Burning Appliances.
• Heaters must not be installed less than 8'
(2.4 m) above the floor. Minimum clearances to
combustibles must be maintained from vehicles
parked below the heater.
• When installed over hoists, minimum
clearances to combustibles must be maintained
from the upper most point of objects on the hoist.
4.4 Electrical
The heater must be electrically grounded in
accordance with the following codes:
United States: Refer to National Electrical
Code®, ANSI/NFPA-70 - latest revision. Wiring
must conform to the most current National
Electrical Code®, local ordinances, and any
special diagrams furnished.
Canada: Refer to Canadian Electrical Code,
CSA C22.1 Part 1 - latest revision.
4.5 Venting
The venting must be installed in accordance with
the requirements within this manual and the
following codes:
United States: Refer to NFPA-54/ANSI Z223.1 latest revision, National Fuel Gas Code.
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.
4.6 High Altitude
These heaters are approved for installations up
to 2000' (610 m)(US), 4500' (1370 m)(Canada)
without modification. Consult factory if US
installation is above 2000' (610 m) or Canadian
installation is above 4500' (1370 m).
7
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 5: HEATER DESCRIPTIONS
5.1 Unitary vs. Multiburner
CTHN-Series burners may be used for unitary
heaters or for multiburner systems.
Unitary heaters consist of a single burner, a single
run of radiant tubing and a single fan assembly. See
Page 14, Figure 13 or See Page 17, Figure 16 for
details.
Multiburner systems consist of more than one burner
and more than one run of radiant tubing. The runs of
radiant tubing are connected together by manifold
tubing. The manifold tubing connects to a single
pump that exhausts the flue gases outdoors. See
Page 32, Figure 19 through Page 35, Figure 23 for
common multiburner system layouts.
Since this manual addresses installation of both
unitary heaters and multiburner systems, pay
close attention to section and figure titles to
verify relevance to unitary heaters or multiburner
systems.
8
SECTION 6: MAJOR COMPONENTS
SECTION 6: MAJOR COMPONENTS
FIGURE 11: Major Component Descriptions
Burner with
Tube Gasket
Must be installed
with the flame
observation window
facing down.
Turbulator
Turbulator must be installed in the last standard section
of tube.Turbulator is only required on the CTHN-40, 60
and 80. For installation, See Page 21, Step 8.8.
Flex Gas Line
with Shut Off Cock
Reflector (Aluminum or Stainless Steel)
Alternate overlap as shown on Page 15,
Figure 14 or on Page 18, Figure 17.
Minimum overlap is 6'' (16 cm).
Burner Tube
Supplied in 10' (3 m) lengths.
Burner tube is always the first
tube after the burner.
Tube
Hot rolled or heat treated aluminized
tube supplied in 10' (3 m) lengths.
Coupling Assembly
with Lock
EP-100 Pump Package For more information, refer to the
EP-100 Installation, Operation and
Service Manual
(P/N 127201NA).
EP-201 Pump Package For more information, refer to
the EP-200 Series Installation,
Operation and Service Manual
(P/N 127200NA).
Tube and Reflector Hanger
with Clamp Package
Position this hanger no more
than 4'' (10 cm) away from
the burner assembly.
Tube and Reflector Hanger
Suspend system from these
hangers.
Reflector Support
Strap & Wire Form
Reflector End Cap
Punch out center section to
accommodate tube.
Restrictor Plate
Used at fan assembly inlet
for unitary heaters only.
See fan assembly below.
Fan Assembly
EP-300 Series
Pump Package For more information,
refer to the EP-300
Series Installation,
Operation and
Service Manual
(P/N 127202NA).
9
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 7: GENERAL SUSPENSION DETAILS
The gas or the electrical supply lines must not be
used to support the heater.
WARNING
Suspension Hazard
Burner is secured to burner tube
by bolts and lockwashers.
Hang heater with materials
with a minimum working
load of 75 lbs (33 kg).
Do not locate the gas or electric supply lines directly
over the path of the flue products from the heater.
The heater must be installed in a location that is
readily accessible for servicing.
The heaters must be installed in accordance with
clearances to combustibles as indicated on the rating
plate and in this instruction manual.
Failure of the supports
can result in death, injury
or property damage.
To ensure your safety and comply with the terms of
the warranty, all units must be installed in
accordance with these instructions.
The minimum and maximum gas inlet pressures
must be maintained as indicated on the rating
plate.Typical installation configurations are shown in
Figure 12.
FIGURE 12: Critical Hanger Placement
Description
S-Hook
Tube/Reflector Hanger
10
Part Number
91907302
03090100
Run Length
Typical Expansion
10' (3 m) - 50' (15 m)
±1" (3 cm)
51' (15.5 m) - 60' (18 m)
±2" (5 cm)
61' (18.6 m) - 80' (24 m)
±3" (8 cm)
Minimum “X” Length
12" (30 cm)
18" (46 cm)
24" (61 cm)
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
8.1 Standard Parts
Table 1: Contents of CTHN Burner Carton
Part No.
Description
CTHN-40 CTHN-60 CTHN-80
CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200
052XXXXX Burner (Rate and Fuel Varies)
1
1
1
1
1
1
1
1
07730400 Restrictor Plate 1.25'' (3.2 cm) dia.
1
-
-
-
-
-
-
-
07730100 Restrictor Plate 1.50'' (3.8 cm) dia.
-
1
-
-
-
-
-
-
07730500 Restrictor Plate 2.25'' (5.7 cm) dia.
-
-
-
1
1
-
-
-
07730600 Restrictor Plate 2.50'' (6.4 cm) dia.
-
-
-
-
-
-
1
-
07730700 Restrictor Plate 2.75'' ( 7 cm) dia.
-
-
-
-
-
1
-
-
03051503 Turbulator Adapter
1
1
1
-
-
-
-
-
03051504 Turbulator Section
2
4
4
-
-
-
-
-
03051505 Turbulator Section,
Stainless Steel
1
-
-
-
-
-
-
-
*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT
(US Models Only)
1
1
1
1
1
-
-
-
*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT
(US Models Only)
-
-
-
-
-
1
1
1
02568200 Gasket (Burner to Burner Tube)
1
1
1
1
1
1
1
1
94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''
4
4
4
4
4
4
4
4
96411600 Split Lock Washer
4
4
4
4
4
4
4
4
91201708 Pipe Nipple 1/2'' NPT x 4''
1
1
1
1
1
1
1
1
152101NA Installation, Operation and Service Manual
1
1
1
1
1
1
1
1
*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.
Table 2: Contents of Core and Extension Packages
Core Packages
Hot Rolled
Part No.
Description
Extension Packages
Aluminized
Hot Rolled
Aluminized
20' 30' 40' 10' 20' 30' 40' 10' 20' 30' 40' 10' 20' 30' 40'
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
91409300 Tube, Hot Rolled Steel, 10' (3 m)
1
2
3
-
-
-
-
1
2
3
4
-
-
-
-
91409408 Tube, HT Aluminized, 10' (3 m)
-
-
-
-
1
2
3
-
-
-
-
1
2
3
4
03051101 Burner Tube, ALUMI-THERM® Steel, 10' (3 m)
-
1
1
-
-
1
1
-
-
-
-
-
-
-
-
03051601 Burner Tube, HT ALUMI-THERM® Steel, 10' (3 m) 1
-
-
1
1
-
-
-
-
-
-
-
-
-
-
01312700 Coupling Assembly
1
2
3
-
1
2
3
1
2
3
4
1
2
3
4
02750303 Standard Reflector, 8' (2.4 m)
3
4
6
2
3
4
6
2
3
4
6
2
3
4
6
02750800 End Cap
2
2
2
2
2
2
2
-
-
-
-
-
-
-
-
03090100 Tube and Reflector Hanger
3
4
5
2
3
4
5
1
2
3
4
1
2
3
4
91907302 S-hook
3
4
5
2
3
4
5
1
2
3
4
1
2
3
4
03050010 Reflector Support Package
(Strap, Wire Form, Screws)
2
3
5
1
2
3
5
2
3
4
6
2
3
4
6
91107720 U-clip Package
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
90502700 Vent Adapter (Not used on CTHN)
1
1
1
1
1
1
1
-
-
-
-
-
-
-
-
01318901 Tube Clamp Package
1
1
1
1
1
1
1
-
-
-
-
-
-
-
-
11
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Table 3: Component Package Guide
Model
Tubing Length
Minimum
Core Packages
Standard
Aluminized
CTHN-40
10' (3 m)
CP10ALUM
CP10ALUM
CTHN-60
20' (6 m)
CP20HRS
CP20ALUM
CTHN-80
20' (6 m)
CP20HRS
CP20ALUM
CTHN-100
30' (9 m)
CP30HRS
CP30ALUM
CTHN-125
40' (12 m)
CP40HRS
CP40ALUM
CTHN-150
40' (12 m)
CP40HRS
CP40ALUM
CTHN-175
50' (15 m)
CP30HRS + EXP20HRS
CP30ALUM + EXP20ALUM
CTHN-200
50' (15 m)
CP30HRS + EXP20HRS
CP30ALUM + EXP20ALUM
Additional tubing length may be added to heater.
Any additional tubing lengths are considered as vent length for length determination.
Maximum venting length for unitary heater is 45' (13.7 m).
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.
Table 4: Common CTHN-Series Components
Part No.
Description
Tubing and Related Accessories
01312700 Coupling, 4" (10 cm) Plain
01312706 Coupling, 6" (15 cm) Plain
0131270I
Coupling, 4" (10 cm) Lined
01331900 Coupling, 4" (10 cm) Damper
E0009356 Coupling, 6" (15 cm) Damper
0133022D Tee, 4" (10 cm) Coated
01330203 Tee, 4" (10 cm) Aluminized
01330204 Tee, 6" (15 cm) Aluminized
0133092D Cross, 4" (10 cm) Coated
01330903 Cross, 4" (10 cm) Aluminized
01330904 Cross, 6" (15 cm) Aluminized
01335801 Elbow, 4" (10 cm) Aluminized 90°
T0100320 Elbow, 6" (15 cm) Aluminized 90°
0133580D Elbow, 4" (10 cm) Coated 90°
01336101 Elbow, 4" (10 cm) Aluminized 45°
0133610D Elbow, 4" (10 cm) Coated 45°
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized
10' (3 m)
91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized
10' (3 m)
91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized
10' (3 m)
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)
E0009105 Tube, 6" (15 cm) dia 10' (3 m)
Heat Treated Aluminized
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia
Aluminized
91240010 Tube Hanger, 6" (15 cm)
91308001 Pipe Compound, High Temperature 1lb can
12
Venting Accessories
01324401 Air Supply Takeoff, 4" (10 cm) Outside
90707501 Air Supply Blower/Power Venter
91409601 Air Flex Duct, 4" (10 cm) Outside
(Box of 8 - 8' (2.4 m) sections)
Reflectors and Related Accessories
01329910 Reflector Side Extension Support
03050010 Reflector Support Package (Tubing)
02712700 Reflector Side Extension, 2 Clips, 2 Screws
02750303 Reflector, Aluminum
027503SS Reflector, Stainless Steel
02750800 Reflector End Cap, Aluminum
027508SS Reflector End Cap, Stainless Steel
027508SH Reflector End Cap, Stainless Steel with Hole
02750900 Reflector Joint
027509SS Reflector Joint, Stainless Steel
027127SS Reflector Side Extension, Stainless Steel
03090100 Tube and Reflector Hanger
91907302 S-hook
91903201 Turnbuckle
91903300 Spring Hook
91903202 Turnbuckle with Eyebolt
Control Packages and Thermostats
02770002 System Control
05023000 Load Relay Package
90417600 Transformer Relay - SPST (12 A)
90436300 Transformer Relay - DPST (12 A)
90423000 Thermostat, 24 V Low Voltage (Marked 1-5)
90424300 Thermostat Guard
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
Deco Grille (1' x 8' [.3 m x 2.4 m])
01363003 Bracket
01365901 End Piece
01326801 Reinforcement
01365903 Joint Piece
91406700 1' x 8' (.3 m x 2.4 m) Protective Grille
01317805
02723014
02730101
02730104
02723016
02730101
02730106
02723034
02730103
02730104
02723036
02730103
02730106
Deco Grille (2' x 4' [.6 m x 1.2 m])
01365900 Shield Frame
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)
Protective Grille
08050001 Grille, 40" (102 cm) Protective
08050002 Protective Grille End Cap
Accessory Package
EP-301 Pump Package 4" (10 cm)
EP-301 Pump Assembly
Accessory Package
EP-301 Pump Package 6" (15 cm)
EP-301 Pump Assembly
Accessory Package
EP-303 Pump Package 4" (10 cm)
EP-303 Pump Assembly
Accessory Package
EP-303 Pump Package 6" (15 cm)
EP-303 Pump Assembly
Accessory Package
Pump Accessories
90430600K Pressure Switch
Starters and Contactors
10050001 Starter, 120 Vac for EP-203, 3 Ø
10050003 Starter, 120 Vac for EP-201, 1 Ø
10050008 Starter, 120 Vac for EP-301, 1 Ø
10050009 Contactor Package120 Vac Coil for EP-301, 230 V, 2 HP
10050010 Starter, 120 Vac for EP-303, 3 Ø
Fan and Pump Packages
05220000 Fan Package 40-150
05221000 Fan Package 175-200
02719105 EP-100 Pump Package
02719100
EP-100 Pump
02724700
Accessory Package
02716305 EP-201 Pump Package
01312001
EP-201 Pump
01317805
Accessory Package
02712034 EP-203 Pump Package
01312002
EP-203 Pump
8.2 Unitary Heater Requirements
CTHN unitary heaters are typically shipped as a
burner package, fan assembly and a tube and
accessory package. The tube and accessory
packages contain enough tube, reflector and hanging
parts for one unitary CTHN heater. Elbows, u-tubes,
controls, and any other parts must be purchased
separately.
See Page 14, Figure 13 for a general overview of a
CTHN unitary heater. CTHN unitary heaters are
controlled by thermostat.
Table 5 summarizes the design requirements for a
CTHN unitary heater.
Table 5: Unitary Heater Design Requirements
Burner Model:
CTHN-40
CTHN-60
CTHN-80
Maximum Number of Burners Allowed
per Fan Assembly (P/N 05220000)
CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200
1
1
1
1
1
1
-
-
Maximum Number of Burners Allowed
per Fan Assembly (P/N 05221000)
-
-
-
-
-
-
1
1
Minimum Radiant Tube Length
10' (3 m)
20' (6 m)
20' (6 m)
30' (9 m)
40' (12 m)
40' (12 m)
50' (15 m)
50' (15 m)
Minimum Distance from Burner to Elbow or
U-Tube
10' (3 m)
10' (3 m)
10' (3 m)
15' (4.5 m) 15' (4.5 m)
20' (6 m)
20' (6 m)
20' (6 m)
13
14
Reflector Support
Tube and Reflector Hanger
Coupling
Burner Tube
Tube Clamp
Package
Burner
Reflector End Cap
Reflector
Fan Assembly
Tube
Turbulator
(With Select Models)
U-Clips
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
8.3 Unitary Linear Heater Layouts
FIGURE 13: Linear Heater Assembly Overview
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
FIGURE 14: Unitary Linear Layout Overviews
b
c
g
d
LEGEND
f
10' (3 m) Tube Length
Burner
Reflector
g
Tube
b
b
c
d
e
Tube/Reflector
Hanger
f
Coupling Assembly
20' (6 m) Tube Length
Fan Assembly
g
a = 14" (36 cm)
reflector width (not shown)
b = 2" (5 cm)
end cap to burner/fan
b
b
c
d
e
e
f
c = 2" (5 cm)
end cap to hanger
30' (9 m) Tube Length
d = 7'6" (229 cm)
distance first hanger
e = 10' (305 cm)
distance between hangers
g
b
b
c
d
e
e
e
f = 9.5" (24 cm)
burner height
g = 17.5" (44 cm)
burner length
f
40' (12 m) Tube Length
g
b
c
b
d
e
e
e
e
f
50' (15 m) Tube Length
15
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 15: Unitary Linear Layout Overviews (Continued)
g
b
c
b
d
e
e
e
e
e
f
60' (18 m) Tube Length
g
b
c
b
d
e
e
e
e
e
e
f
70' (21 m) Tube Length
g
b
c
b
d
e
f
80' (24 m) Tube Length
16
e
e
e
e
e
e
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
8.4 Unitary U-tube Heater Layouts
CTHN-Series heaters (except CTHN-40) are
approved for optional u-tube configurations.
The u-tube may be installed in either a standard
horizontal position, 45° position or in an opposite 45°
position as shown on Page 5, Figure 5 through
Figure 7. When using a u-tube configuration, the
following additional rules must be adhered to:
• A minimum of 10' (3 m) on CTHN-60/80, a
minimum of 15' (4.5 m) on CTHN-100/125, and a
minimum of 20' (6 m) on CTHN-150/175/200 is
required between the burner and the u-tube.
• For turbulator installation, See Page 21, Step 8.8.
• The burner must never be operated
in a tilted position.
The heater must be properly supported at all
locations. See Page 10, Figure 12.
FIGURE 16: U-tube Assembly Overview
U-tube
Support Bracket
Reflector
Support
Burner
Tube Clamp
Package
Burner
Tube
Turbulator
(With Select
Models)
Tube
Reflector
U-tube, Standard
1
Couplings
2
U-clips
Reflector
End Caps
U-tube, Full 45°
U-bolt
1 4"Tight
(10 cm) u-bolt,
2
secured to burner tube
with 1/4" (6 mm)
lockwashers and
1/4-20 hex nuts.
2
Loose U-bolt
4" (10 cm) u-bolt,
secured to bracket with
1/4" (6 mm) lockwashers
and 1/4-20 hex nuts on
top and bottom to
allow for tube expansion
and contraction.
1
U-tube, Opposite 45°
1
2
U-tube
18" (457 mm)
Center to Center
U-bolt
Nut
Lock Washer
Lock Washer
Nut
17
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 17: Unitary U-tube Layout Overviews
g
b
c
LEGEND
e
Burner
20' (6 m)*
Tube Length
h
Reflector
g
b
c
Tube
d
f
Tube/Reflector
Hanger
Coupling Assembly
30' (9 m)
Tube Length
h
U-tube
g
b
c
d
Fan Assembly
(not shown)
e
a = 14" (36 cm)
reflector width (not shown)
40' (12 m)
Tube Length
b = 2" (5 cm)
end cap to burner
h
g
50' (15 m)*
Tube Length
b
c
c = 2" (5 cm)
end cap to hanger
d
e
f
d = 7'6" (229 cm)
distance first hanger
e = 10' (305 cm)
distance between hangers
h
g
b
c
f = 5' (153 cm)
distance between last full tube
hanger and half tube hanger
d
e
e
g = 9.5" (24 cm) burner length
h = 17.5" (44 cm) burner height
60' (18 m)
Tube Length
h
g
70' (21 m)
Tube Length
18
b
c
d
e
e
d
e
e
f
h
g
80' (24 m)
Tube Length
*20' (6 m) & 50' (15 m) tube length
heaters require the last reflector
before the u-tube to be cut in
half for use on both sides.
h
b
c
e
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
Step 8.5 Burner Tube Installation
NOTE:
Tubing requires a downward
slope of 1/2" (13 mm)
per 20' (6 m) away
from burner.
Offset mounting
hole must be
to the top.
S-hook
Hanger
Burner Tube
Weld seam
must be to the
bottom of the tube.
7' 6" ± 1'
(229 cm ± 25 cm)
Description
Burner Tube
S-hook
Tube/Reflector Hanger
Part Number
03051XXX
91907302
03090100
Step 8.6 Tube Clamp Package Installation
Description
Tube Clamp Package
Tube Clamp
Bolt
Flat Washer
Nut
Part Number
01318901
01396801
97113940
95211600
92113900
Tube Clamp
Bolt
Flat
Washer
Nut
(torque 120 in/lb
13.56 Nm)
19
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 8.7 Coupling and Tube Assembly
coupling
A Close
with tab.
slide bar/coupling lock
B Start
onto coupling.
Tab
Slide Bar/Coupling Lock
Wide End
Coupling
Open
3" (8 cm) to
4" (10 cm)
Closed
C Insert tubes into coupling.
D Tighten coupling to join tubes.
Slide Bar/Coupling Lock
Coupling
Orient coupling so that
the impact block is in the
2:00 or 10:00 o’clock
positions
Tube
Tube
Tube
Description
Coupling
Slide Bar/Coupling Lock
Tube
Part Number
01329600
01329700
91409XXX
Step 8.7.1 Coupling and Tube Assembly (Continued)
Tighten slide bar as shown below.
Drive slide bar until tight.
End of slide bar should be
within tolerance listed below.
± 2" (5 cm)
Correct Slide Bar
dimensions
Incorrect Slide Bar
position
• Repeat Step 8.7, A - D until all tubes are assembled. See Page 21, Step 8.7.2.
NOTE: If coupling is not tight, loss of vacuum can occur.
20
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
Step 8.7.2 Coupling and Tube Assembly (Continued)
Radiant
Tube Length
10' (4.5 m)
20' (6 m)
20' (6 m)
30' (9 m)
40' (12 m)
40' (12 m)
50' (18 m)
50' (18 m)
Model
CTHN-40
CTHN-60
CTHN-80
CTHN-100
CTHN-125
CTHN-150
CTHN-175
CTHN-200
2.3 m
.25 m
3m
.25 m
Step 8.8 Turbulator Installation
Turbulator must be installed in the last
standard section of radiant tube.
Turbulator is only required on the
CTHN-40, CTHN-60 and CTHN-80.
Twis t
Turbulator
Section
Turbulator
Adapter
Tab
Turbulator section
(stainless) used in
CTHN-40 heaters must be in the
section of tube nearest to the burner.
Description
Turbulator Adapter
Turbulator Section
Turbulator Section (Stainless)
Tube
Turbulator Installation
Model
Tube Section
CTHN-40
1st 10' (3 m) Section
CTHN-60
2nd 10' (3 m) Section
CTHN-80
2nd 10' (3 m) Section
CTHN-100
N/A
CTHN-125
N/A
CTHN-150
N/A
CTHN-175
N/A
CTHN-200
N/A
Pull String
Fold tab around outside
of tube nearest to the vent to
hold turbulator in place.
Part Number
03051503
03051504
03051505
91409XXX
21
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 8.9 Reflector Installation
NOTE: All radiant tube surfaces
must be covered by a reflector,
except for a u-tube. Manifold tube
may or may not be covered.
Hanger
Burner Tube
Reflector
Description
Tube/Reflector Hanger
Burner Tube
Reflector
22
Part Number
03090100
03051XXX
02750303
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
Step 8.9.1 Reflector, U-clip and Reflector Support Installation
reflector supports and u-clips depend on the
The pictorial drawings of the heater construction in
Section 8 are schematic only and provide a general individual installation. Use either pop rivets or sheet
guideline of where hangers, reflector supports and
metal screws instead of u-clips when installing end
u-clips are to be installed.
caps and joint pieces in areas where impact and high
wind may be a factor. The following rules must be
To ensure proper expansion and contraction
movement of the reflectors, a combination of u-clips observed.
and reflector supports are used. The positioning of
1. The first reflector after the burner must be affixed in
the middle of the reflector with a reflector support and
tight screws.
Tight
Sheet Metal
Screw
Wire Form
Reflector
End Cap
First Reflector
Reflector Support
Strap
U-clips
Overlap must be a
minimum of 6" (16 cm).
2B
Slip Overlap
6"
(16 cm)
2. The overlap at the first and second reflector is a slip overlap.
Thereafter, every third reflector joint is a slip overlap. A slip
overlap is achieved by either:
a.) both reflectors lay inside a hanger.
(No reflector support needed.)
b.) using a reflector support with
loose screws at the reflector
overlap.
Loose screws
loosened 1/16"
(2 mm) to allow
slippage.
2A
Slip Overlap
3A
Non-Slip Overlap
3. The remaining reflector overlaps require a non-slip
overlap connection. To affix the reflectors together in
a non-slip overlap either:
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger, u-clips or
sheet metal screws may be used.
This section of three reflectors joined together must
be affixed to the tube with at least one reflector support
with tight screws.
Description
Reflector Support Package
Wire Form
Reflector Support Strap
Screw #8 x 3/4
U-clip Package
Reflector End Cap
Part Number
03050010
91908004
03050000
94320812
91107720
027508XX
Reflector
Reflector
Support
Reflector
Tight
Screws
3B
Non-Slip Overlap
U-clip
(2 clips per
non-slip overlap
inside a hanger)
23
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 8.10 Burner Installation
Burner
Gasket
S-hook
Burner Tube
Burner must be installed
with the flame observation
window facing down.
Description
Bolt
Burner
Lock Washer
Gasket
Lock
Washer
Part Number
94273914
052XXXXX
96411600
02568200
Bolt
(Torque 120 in/lb
13.56 Nm)
Step 8.11 Fan Inlet Plate and Warning Tag
Remove the warning tag and inlet collar
from fan inlet.
IMPORTANT!
Remove this tag and install
the restrictor plate before
assembling fan to the tube.
IMPORTANT!
Remove this tag and install
the restrictor plate before
assembling fan to the tube.
24
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION
Step 8.12 Restrictor Plate Installation
Attach restrictor plate (see chart below right) to
fan inlet and replace inlet collar.
Description
Restrictor Plate
Model
CTHN-40
CTHN-60
CTHN-80
CTHN-100
CTHN-125
CTHN-150
CTHN-175
CTHN-200
Part Number
07730XXX
Fan Assy. P/N
05220000
05220000
05220000
05220000
05220000
05220000
05221000
05221000
Restrictor Plate P/N
07730400 1.25'' dia
07730100 1.50'' dia
NONE
07730500 2.25'' dia
07730500 2.25'' dia
07730700 2.75'' dia
07730600 2.50'' dia
NONE
Step 8.13 Fan Installation
Fold tab around outside
of tube nearest to the
vent to hold turbulator
in place.
Remove warning tag from fan inlet
and install restrictor plate if required.
See Step 8.12.
Last Tube
Turbulator not required
for all models. (See Page 21,
Step 8.8 for details.)
Tighten securely
until tube cannot
be removed.
Vent Adapter
Description
Fan Assembly 40 -150
Fan Assembly 175-200
Part Number
05220000
05221000
Fan Assembly
25
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 9: MULTIBURNER HEATER INSTALLATION
9.1 Standard Parts
Table 6: Contents of CTHN Burner Carton
Part No.
Description
CTHN-40 CTHN-60 CTHN-80
CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200
052XXXXX Burner (Rate and Fuel Varies)
1
1
1
1
1
1
1
1
07730400 Restrictor Plate 1.25'' (3.2 cm) dia.
1
-
-
-
-
-
-
-
07730100 Restrictor Plate 1.50'' (3.8 cm) dia.
-
1
-
-
-
-
-
-
07730500 Restrictor Plate 2.25'' (5.7 cm) dia.
-
-
-
1
1
-
-
-
07730600 Restrictor Plate 2.50'' (6.4 cm) dia.
-
-
-
-
-
-
1
-
07730700 Restrictor Plate 2.75'' ( 7 cm) dia.
-
-
-
-
-
1
-
-
03051503 Turbulator Adapter
1
1
1
-
-
-
-
-
03051504 Turbulator Section
2
4
4
-
-
-
-
-
03051505 Turbulator Section, Stainless Steel
1
-
-
-
-
-
-
-
*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT
(US Models Only)
1
1
1
1
1
-
-
-
*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT
(US Models Only)
-
-
-
-
-
1
1
1
02568200 Gasket (Burner to Burner Tube)
1
1
1
1
1
1
1
1
94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''
4
4
4
4
4
4
4
4
96411600 Split Lock Washer
4
4
4
4
4
4
4
4
91201708 Pipe Nipple 1/2'' NPT x 4''
1
1
1
1
1
1
1
1
152101NA Installation, Operation and Service Manual
1
1
1
1
1
1
1
1
*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.
Table 7: Contents of Core and Extension Packages
Core Packages
Hot Rolled
Part No.
Description
Extension Packages
Aluminized
Hot Rolled
Aluminized
20' 30' 40' 10' 20' 30' 40' 10' 20' 30' 40' 10' 20' 30' 40'
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
(3m)
(6m)
(9m)
(12m)
91409300 Tube, Hot Rolled Steel, 10' (3 m)
1
2
3
-
-
-
-
1
2
3
4
-
-
-
-
91409408 Tube, HT Aluminized, 10' (3 m)
-
-
-
-
1
2
3
-
-
-
-
1
2
3
4
03051101 Burner Tube, ALUMI-THERM® Steel, 10' (3 m)
-
1
1
-
-
1
1
-
-
-
-
-
-
-
-
03051601 Burner Tube, HT ALUMI-THERM® Steel, 10' (3 m) 1
-
-
1
1
-
-
-
-
-
-
-
-
-
-
01312700 Coupling Assembly
1
2
3
-
1
2
3
1
2
3
4
1
2
3
4
02750303 Standard Reflector, 8' (2.4 m)
3
4
6
2
3
4
6
2
3
4
6
2
3
4
6
02750800 End Cap
2
2
2
2
2
2
2
-
-
-
-
-
-
-
-
03090100 Tube and Reflector Hanger
3
4
5
2
3
4
5
1
2
3
4
1
2
3
4
91907302 S-hook
3
4
5
2
3
4
5
1
2
3
4
1
2
3
4
03050010 Reflector Support Package
(Strap, Wire Form, Screws)
2
3
5
1
2
3
5
2
3
4
6
2
3
4
6
91107720 U-clip Package
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
90502700 Vent Adapter (Not used on CTHN)
1
1
1
1
1
1
1
-
-
-
-
-
-
-
-
01318901 Tube Clamp Package
1
1
1
1
1
1
1
-
-
-
-
-
-
-
-
26
SECTION 9: MULTIBURNER HEATER INSTALLATION
Table 8: Component Package Guide
Tubing Length
Model
Minimum
Core Packages
Standard
Aluminized
CTHN-40
20' (6 m)
CP20HRS
CP10ALUM
CTHN-60
30' (9 m)
CP30HRS
CP20ALUM
CTHN-80
30' (9 m)
CP30HRS
CP20ALUM
CTHN-100
40' (12 m)
CP40HRS
CP30ALUM
CTHN-125
50' (15 m)
CP30HRS + EXP20HRS
CP40ALUM
CTHN-150
50' (15 m)
CP30HRS + EXP20HRS
CP40ALUM
CTHN-175
60' (18 m)
CP30HRS + EXP30HRS
CP30ALUM + EXP30ALUM
CTHN-200
60' (18 m)
CP30HRS + EXP30HRS
CP30ALUM + EXP30ALUM
Additional tubing length may be added to heater.
Any additional tubing lengths are considered as manifold tube length for length determination, See Page 29,
Section 9.2 through Page 31, Section 9.6, design requirements and allowed manifold tube lengths.
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.
Table 9: Common CTHN-Series Components
Part No.
Description
Tubing and Related Accessories
01312700 Coupling, 4" (10 cm) Plain
01312706 Coupling, 6" (15 cm) Plain
0131270I
Coupling, 4" (10 cm) Lined
01331900 Coupling, 4" (10 cm) Damper
E0009356 Coupling, 6" (15 cm) Damper
0133022D Tee, 4" (10 cm) Coated
01330203 Tee, 4" (10 cm) Aluminized
01330204 Tee, 6" (15 cm) Aluminized
0133092D Cross, 4" (10 cm) Coated
01330903 Cross, 4" (10 cm) Aluminized
01330904 Cross, 6" (15 cm) Aluminized
01335801 Elbow, 4" (10 cm) Aluminized 90°
T0100320 Elbow, 6" (15 cm) Aluminized 90°
0133580D Elbow, 4" (10 cm) Coated 90°
01336101 Elbow, 4" (10 cm) Aluminized 45°
0133610D Elbow, 4" (10 cm) Coated 45°
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized
10' (3 m)
91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized
10' (3 m)
91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized
10' (3 m)
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)
E0009105 Tube, 6" (15 cm) dia 10' (3 m)
Heat Treated Aluminized
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia
Aluminized
91240010 Tube Hanger, 6" (15 cm)
91308001 Pipe Compound, High Temperature 1lb can
Venting Accessories
01324401 Air Supply Takeoff, 4" (10 cm) Outside
90707501 Air Supply Blower/Power Venter
91409601 Air Flex Duct, 4" (10 cm) Outside
(Box of 8 - 8' (2.4 m) sections)
Reflectors and Related Accessories
01329910 Reflector Side Extension Support
03050010 Reflector Support Package (Tubing)
02712700 Reflector Side Extension, 2 Clips, 2 Screws
02750303 Reflector, Aluminum
027503SS Reflector, Stainless Steel
02750800 Reflector End Cap, Aluminum
027508SS Reflector End Cap, Stainless Steel
027508SH Reflector End Cap, Stainless Steel with Hole
02750900 Reflector Joint
027509SS Reflector Joint, Stainless Steel
027127SS Reflector Side Extension, Stainless Steel
03090100 Tube and Reflector Hanger
91907302 S-hook
91903201 Turnbuckle
91903300 Spring Hook
91903202 Turnbuckle with Eyebolt
Thermostats
02770002
05023000
90417600
90436300
90423000
90424300
System Control
Load Relay Package
Transformer Relay - SPST (12 A)
Transformer Relay - DPST (12 A)
Thermostat, 24 V Low Voltage (Marked 1-5)
Thermostat Guard
Deco Grille (1' x 8' [.3 m x 2.4 m])
01363003 Bracket
01365901 End Piece
27
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
01326801
01365903
91406700
Reinforcement
Joint Piece
1' x 8' (.3 m x 2.4 m) Protective Grille
Deco Grille (2' x 4' [.6 m x 1.2 m])
01365900 Shield Frame
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)
Protective Grille
08050001 Grille, 40" (102 cm) Protective
08050002 Protective Grille End Cap
Fan and Pump Packages
05220000 Fan Package 40-150
05221000 Fan Package 175-200
02719105 EP-100 Pump Package
02719100
EP-100 Pump
02724700
Accessory Package
02716305 EP-201 Pump Package
01312001
EP-201 Pump
01317805
Accessory Package
02712034 EP-203 Pump Package
01312002
EP-203 Pump
01317805
Accessory Package
02723014 EP-301 Pump Package 4" (10 cm)
02730101
EP-301 Pump Assembly
02730104
Accessory Package
02723016 EP-301 Pump Package 6" (15 cm)
02730101
EP-301 Pump Assembly
02730106
Accessory Package
02723034 EP-303 Pump Package 4" (10 cm)
02730103
EP-303 Pump Assembly
02730104
Accessory Package
02723036 EP-303 Pump Package 6" (15 cm)
02730103
EP-303 Pump Assembly
02730106
Accessory Package
Pump Accessories
90430600K Pressure Switch
Starters and Contactors
10050001 Starter, 120 Vac for EP-203, 3 Ø
10050003 Starter, 120 Vac for EP-201, 1 Ø
10050008 Starter, 120 Vac for EP-301, 1 Ø
10050009 Contactor Package120 Vac Coil for EP-301, 230 V, 2 HP
10050010 Starter, 120 Vac for EP-303, 3 Ø
28
SECTION 9: MULTIBURNER HEATER INSTALLATION
9.2 Multiburner System Design Requirements
A CTHN multiburner system has a number of radiant
tube sections interconnected by manifold tube to a
pump to form a complete system. Reflectors can be
used over the manifold tube but are not required.
The system design parameters are such that the
manifold sections are not subjected to condensate
when the system is fully heated up. It is required that
heat-treated aluminized or coated tubing is used for
the manifold to increase system life and to handle
initial condensation during start-up. Damper
couplings may be necessary to balance system
vacuum.
Design requirements for a CTHN multiburner system
are summarized on Page 30, Table 10.
CTHN multiburner heaters are typically shipped as
burner packages and tube and accessory packages.
The tube and accessory packages contain enough
tube, reflector and hanging parts for the radiant
section of one CTHN heater. Elbows, tees, manifold
tube, pumps, controls, damper couplings and any
other parts used beyond the burner, radiant tube and
reflector must be purchased separately. See Figure
18 for a general overview of a simple CTHN
multiburner system. Depending on system
requirements, CTHN multiburner systems may be
controlled by either a ROBERTS GORDON® System
Control (shown) or by a relay system.
FIGURE 18: Typical CTHN Multiburner System Installation
Zone 1 Thermostat
T
System Control (optional)
Turbulator (if required)
Pressure Switch
Cross
Optional Reflector
Tee
Pump
Manifold Tube
Exhaust to
Outside
Radiant Tube
Burners
T
Zone 2 Thermostat
Drawing Not to Scale
29
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Table 10: Multiburner Design Requirements
Burner Model:
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200
Radiant Tube Length
20' (6 m)
30' (9 m)
30' (9 m)
40' (12 m)
50' (15 m)
50' (15 m)
60' (18 m)
60' (18 m)
Minimum Manifold Tube Length per Burner
3' (1 m)
3' (1 m)
3' (1 m)
6' (2 m)
6' (2 m)
10' (3 m)
10' (3 m)
10' (3 m)
Maximum Manifold Tube Length per
Burner
30' (9 m) 35' (10.5 m) 40' (12 m) 45' (13.5 m)
50' (15 m)
55' (16.5 m)
60' (18 m)
60' (18 m)
Minimum Distance from Burner to Elbow
or U-tube
10' (3 m)
10' (3 m)
10' (3 m)
15' (4.5 m)
15' (4.5 m)
20' (6 m)
20' (6 m)
20' (6 m)
2
2
2
2
2
2
2
2
Elbows Allowed per Burner*
* U-tube = 2 elbows
9.3 Burners Per Pump
1. The maximum number of burners per pump is
shown in Table 11.
b. EP-200 up to 750,000 Btu/h max, but not
more than 6 burners.
c. EP-300 up to 1,600,000 Btu/h max, number
of burners is limited to the maximum
number of burners listed in Table 11 for the
largest input model used.
2. When combining different burner inputs in a
system, the number of burners per pump (0' 2,000' altitude) is given by the sum of their
inputs:
a. EP-100 up to 500,000 Btu/h max, but not
more than 4 burners.
Table 11: Number of Burners Allowed Per Pump
Pump Model
EP-100
EP-200 Series
EP-300 Series
30
Altitude
CTHN-40
CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200
0' - 2,000'
4
4
4
4
4
3
2
2
2,001' - 3,000'
4
4
4
4
3
3
2
2
3,001' - 4,000'
4
4
4
4
3
2
2
2
4,001' - 5,000'
4
4
4
4
3
2
2
2
5,001' - 6,000'
4
4
4
4
3
2
2
2
6,001' - 7,000'
4
4
4
3
3
2
2
2
7,001' - 8,000'
4
4
4
3
3
2
2
1
8,001' - 9,000'
4
4
4
3
2
2
2
1
0' - 2,000'
6
6
6
6
6
5
4
4
2,001' - 3,000'
6
6
6
6
6
5
4
3
3,001' - 4,000'
6
6
6
6
5
4
4
3
4,001' - 5,000'
6
6
6
6
5
4
4
3
5,001' - 6,000'
6
6
6
6
5
4
3
3
6,001' - 7,000'
6
6
6
6
5
4
3
3
7,001' - 8,000'
6
6
6
6
5
4
3
3
8,001' - 9,000'
6
6
6
6
5
4
3
3
0' - 2,000'
16
16
14
12
12
10
8
8
2,001' - 3,000'
16
16
14
12
12
9
8
7
3,001' - 4,000'
16
16
14
12
11
9
8
7
4,001' - 5,000'
16
16
14
12
10
9
7
6
5,001' - 6,000'
16
16
14
12
10
8
7
6
6,001' - 7,000'
16
16
14
12
10
8
7
6
7,001' - 8,000'
16
16
14
12
10
8
6
6
8,001' - 9,000'
16
16
14
12
10
8
6
6
SECTION 9: MULTIBURNER HEATER INSTALLATION
9.4 Radiant Tube Length
The radiant tube length fixed for each burner is
shown on Page 30, Table 10.
9.5 Manifold Tube
Any tube beyond the radiant tube length is
considered manifold. Manifold tube can be used to
lengthen tube runs beyond the radiant tube length; to
connect multiple runs of tubing and connect the
system to the pump. Minimum and maximum
manifold tube lengths are shown on Page 30,
Table 10. The table must be used in conjunction
with the additional rules for the diameter and
length of manifold in a system, as described on
Page 31, Section 9.5.1 through Page 35, Section
9.6.3.
9.5.1 Manifold Diameter
1. Manifold diameter for systems containing less
than 320,000 Btu/h input can be 4" (10 cm) or
6" (15 cm).
2. Manifold diameter for systems containing
320,000 Btu/h input and greater must be 6"
(15 cm).
Exception: If total manifold tube length is 70'
(21 m) or less, 4" (10 cm) diameter manifold
tube can be used for systems up to
800,000 Btu/h.
9.6 Multiburner System Layouts and Manifold
Tube Length Rules
Most CTHN multiburner layouts can be classified as
one of the following five layout types:
Flag, Modified In-Series, T, Fork or Herringbone.
Please refer to Page 31, Section 9.6.1 through Page
35, Section 9.6.3 for explanation of manifold rules
and basic diagrams of each layout type. The
diagrams show very simple examples of each layout
type. Actual layouts will vary in total number of
burners in the system as well as the overall shape of
the system. Additional pieces such as elbows may
change the overall layout appearance but are usually
considered a variant of one of the five multiburner
layout types.
9.6.1 Flag and Modified In-Series Layouts and
Manifold Tube Length Rules
See Page 32, Figure 19 through Page 32, Figure 20
for diagrams of Flag and Modified In-Series layouts.
Minimum and maximum manifold tube length applies
to all tubing between the end of a radiant tube run
and a tee or cross; all tubing between any tees and/
or crosses; and all tubing between the last tee or
cross and the pump. See Page 30, Table 10.
Example: Consider a Flag or Modified In-Series
layout with five CTHN-100 burners. Page 30, Table 10
shows a minimum of 6' (2 m) and a maximum of 45'
(13.5 m) of manifold tube required per burner.
Therefore the entire five-burner system must have
between 30' (10 m) and 225' (69 m) of manifold
tubing. The manifold tubing is in addition to the 40'
(12 m) of radiant tube per burner. Radiant tube may
end at a tee, or runs may be lengthened by adding
some manifold tube between the end of the radiant
tube and a tee. Each burner in the system (except for
the burner furthest from the pump) must use a
damper coupling to properly adjust the vacuum at
each burner. The damper coupling may be placed
anywhere between the end of the radiant pipe and
the tee.
31
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 19: Flag Layout
FIGURE 20: Modified In-Series Layout
Multiple rows of burners:
pump placed at the end of the manifold tube.
Burner furthest from pump
does not need a damper coupling.
Multiple burners:
pump placed at the end of the manifold tube.
A variation on the flag layout.
First Tee
First Tee
Manifold tube
between radiant
tube ends.
Last Tee
Pump
Burner
Last Tee
Burner
Manifold tube
between joining
tee and pump.
Pump
32
SECTION 9: MULTIBURNER HEATER INSTALLATION
9.6.2 T and Fork Layouts and Manifold Tube
Length Rules
See Page 33, Figure 21 through Page 34, Figure 22
for diagrams of T and Fork layouts. The T and Fork
layouts have a tee or cross (called the "last tee" or
"last cross") where the combustion gases in the
system enter the tee or cross with directly opposing
flow directions, which creates an added source of
pressure drop in the system. This additional source
of pressure drop requires some difference in how the
allowed manifold length is calculated. In this case,
we have to differentiate manifold tube that is located
between the radiant pipe and the last tee (or cross)
from manifold tube that is located between the last
tee (or cross) and the pump.
First determine the length of manifold tube between
the radiant tube end and the last tee (or cross). Do
not count any tube length twice. Now refer to Page
30, Table 10 and find the maximum manifold tube
length for each burner. Add together the maximum
manifold tube length on the table for each burner in
the system, this is the maximum manifold tube length
for the entire system.
To determine the maximum manifold tube allowed
between the last tee (or cross) and the pump:
Subtract the manifold tube length between the
radiant tube and the last tee (or cross) from the
maximum manifold length for the entire system, then
divide that number by 1.5.
Example: Consider a T layout with two CTHN-100
burners. See Page 33, Figure 21. Assume that 15'
(4.5 m) of manifold was used from each radiant tube
end to the last tee. Page 30, Table 10 indicates that
each CTHN-100 burner can have a maximum of 45'
(13.5 m) of manifold tube. Therefore the maximum
manifold tube length amount allowed between the
last tee and the pump in this case is
([45' + 45']-[15' x 2])/1.5 = 40' or in metric,
([13.5 m + 13.5 m]-[4.5 m x 2])/1.5 = 12 m.
FIGURE 21: T Layout
One pair of burners.
Last Tee
Burner
Manifold tube between joining tee
and pump.
Pump
33
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 22: Fork Layout
Multiple rows of burners:
Manifold tube between the last tee or cross and
the pump is perpendicular to the manifold tube
joining the rows. Pump is not required to be
placed in the center of the system (as shown).
Pump
Manifold tube between
radiant tube ends.
Manifold tube between
joining cross and pump.
Tee (2)
Last Cross
Damper Couplings
located at the end of
the rows.
Radiant Tube
Burner
34
SECTION 9: MULTIBURNER HEATER INSTALLATION
the connecting tee or cross.
9.6.3 Herringbone Layout and Manifold Tube
Length Rules
The herringbone layout is essentially several T
layouts stacked together. Therefore, the same
principle for manifold tube calculation as used for T
layouts is used for herringbone layouts, with one
exception. In a herringbone layout, the manifold
tube length between tees (or crosses) as well as
between the last tee (or cross) and the pump is
calculated by dividing by 1.5 as shown in the T
example on Page 33, Section 9.6.2. The only
manifold tube length in a herringbone layout that is
not divided by 1.5 is any manifold tube length located
between the end of the radiant tube and a tee or
cross.
Example: Consider a herringbone layout similar to
the layout on the left in Figure 23, having ten CTHN100 burners. Assume that each heater has 40' (12m)
of radiant tube and 10'(3m) of manifold tube before
According to Table 10 each burner must have at least
40' (12m) of radiant tube, also each burner must
have between 6' (2m) and 45' (13.5m) of manifold
tube. Each burner has already met the minimum
manifold pipe requirement due to the 10' (3m) of
manifold tube before the connecting tees and
crosses. The maximum manifold tube length for the
entire system is 10 burners X 45' (13.5m) = 450'
(135m). Subtract the 100' (30m) that has already
been used before the connecting tees/crosses and
350' (105m) remains.
Since the remaining manifold is located either
between or after connecting tees or crosses, the
manifold length must be divided by 1.5. 350' (105m)/
1.5 = 233' (70m). Therfore, up to 233' (70m) can be
used between the branches and also between the
last cross and the pump.
FIGURE 23: Herringbone Layout
Multiple opposing rows of burners: pump placed at the end of the manifold tube or somewhere between
the burners.
Tee
Tee
Manifold tube between
radiant tube ends.
Cross (3)
Pump
Last Tee
Burner
Last Cross
Manifold tube
between joining
tee and pump.
Pump
35
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 9.7 Burner Tube Installation
NOTE:
Tubing requires a downward
slope of 1/2" (13 mm)
per 20' (6 m) away
from burner.
Offset mounting
hole must be
to the top.
S-hook
Hanger
Burner Tube
Weld seam
must be to the
bottom of the tube.
7' 6" ± 1'
(229 cm ± 25 cm)
Description
Burner Tube
S-Hook
Tube/Reflector Hanger
Part Number
03051XXX
91907302
03090100
Step 9.8 Tube Clamp Package Installation
Description
Tube Clamp Package
Tube Clamp
Bolt
Flat Washer
Nut
Part Number
01318901
01396801
97113940
95211600
92113900
Tube Clamp
Flat
Washer
Nut
(torque 120 in/lb
13.56 Nm)
36
Bolt
SECTION 9: MULTIBURNER HEATER INSTALLATION
Step 9.9 Coupling and Tube Assembly
coupling
A Close
with tab.
slide bar/coupling lock
B Start
onto coupling.
Tab
Slide Bar/Coupling Lock
Wide End
Coupling
Open
3" (8 cm) to
4" (10 cm)
Closed
C Insert tubes into coupling.
D Tighten coupling to join tubes.
Slide Bar/Coupling Lock
Coupling
Orient coupling so that
the impact block is in the
2:00 or 10:00 o’clock
positions
Tube
Tube
Tube
Description
Coupling
Slide Bar/Coupling Lock
Tube
Part Number
01329600
01329700
91409XXX
Step 9.9.1 Coupling and Tube Assembly (Continued)
Tighten slide bar as shown below.
Drive slide bar until tight.
End of slide bar should be
within tolerance listed below.
± 2" (5 cm)
Correct Slide Bar
dimensions
Incorrect Slide Bar
position
• Repeat Step 9.9 on Page 37, A - D until all tubes are assembled. See Page 38, Step 9.9.2.
NOTE: If coupling is not tight, loss of vacuum can occur.
37
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 9.9.2 Coupling and Tube Assembly (Continued)
Radiant
Tube Length
10' (4.5 m)
20' (6 m)
20' (6 m)
30' (9 m)
40' (12 m)
40' (12 m)
50' (18 m)
50' (18 m)
Model
CTHN-40
CTHN-60
CTHN-80
CTHN-100
CTHN-125
CTHN-150
CTHN-175
CTHN-200
2.3 m
.25 m
3m
.25 m
Step 9.10 Turbulator Installation
Turbulator must be installed in the last
standard section of radiant tube.
Turbulator is only required on the
CTHN-40, CTHN-60 and CTHN-80.
Twis t
Turbulator
Section
Turbulator
Adapter
Tab
Turbulator section
(stainless) used in
CTHN-40 heaters must be
in the section of tube nearest
to the burner.
Description
Turbulator Adapter
Turbulator Section
Turbulator Section (Stainless)
Tube
38
Turbulator Installation
Model
Tube Section
CTHN-40
1st 10' (3 m) Section
CTHN-60
2nd 10' (3 m) Section
CTHN-80
2nd 10' (3 m) Section
CTHN-100
N/A
CTHN-125
N/A
CTHN-150
N/A
CTHN-175
N/A
CTHN-200
N/A
Pull String
Fold tab around outside
of tube nearest to the vent to
hold turbulator in place.
Part Number
03051503
03051504
03051505
91409XXX
SECTION 9: MULTIBURNER HEATER INSTALLATION
Step 9.11 Reflector Installation
NOTE: All radiant tube surfaces
must be covered by a reflector,
except for a u-tube. Manifold tube
may or may not be covered.
Hanger
Burner Tube
Reflector
Description
Tube/Reflector Hanger
Burner Tube
Reflector
Part Number
03090100
03051XXX
02750303
39
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 9.11.1 Reflector, U-clip and Reflector Support Installation
reflector supports and u-clips depend on the
The pictorial drawings of the heater construction in
Section 9 are schematic only and provide a general individual installation. Use either pop rivets or sheet
guideline of where hangers, reflector supports and
metal screws instead of u-clips when installing end
u-clips are to be installed.
caps and joint pieces in areas where impact and high
wind may be a factor. The following rules must be
To ensure proper expansion and contraction
movement of the reflectors, a combination of u-clips observed.
and reflector supports are used. The positioning of
1. The first reflector after the burner must be affixed in
the middle of the reflector with a reflector support and
tight screws.
Tight
Sheet Metal
Screw
Wire Form
Reflector
End Cap
First Reflector
Reflector Support
Strap
U-clips
Overlap must be a
minimum of 6" (16 cm).
2B
Slip Overlap
6"
(16 cm)
2. The overlap at the first and second reflector is a slip overlap.
Thereafter, every third reflector joint is a slip overlap. A slip
overlap is achieved by either:
a.) both reflectors lay inside a hanger.
(No reflector support needed.)
b.) using a reflector support with
loose screws at the reflector
overlap.
Loose screws
loosened 1/16"
(2 mm) to allow
slippage.
2A
Slip Overlap
3A
Non-Slip Overlap
3. The remaining reflector overlaps require a non-slip
overlap connection. To affix the reflectors together in
a non-slip overlap either:
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger, u-clips or
sheet metal screws may be used.
This section of three reflectors joined together must
be affixed to the tube with at least one reflector support
with tight screws.
Description
Reflector Support Package
Wire Form
Reflector Support Strap
Screw #8 x 3/4
U-clip Package
Reflector End Cap
40
Part Number
03050010
91908004
03050000
94320812
91107720
027508XX
Reflector
Reflector
Support
Reflector
Tight
Screws
3B
Non-Slip Overlap
U-clip
(2 clips per
non-slip overlap
inside a hanger)